dana spicer drive axles...• use this book to order parts for your dana® spicer® axle. • for...

AXIP-0342 07/04 PDFPrinted in USA

The Roadranger® System is an unbeatable combination of the best products from Eaton and Dana – partnering to provide you the most advanced, most trouble-free drivetrain in the industry. And it's backed by the Roadrangers – the most experienced, most expert, most accessible drivetrain consultants in the business. Visit our web site at www.roadranger.com. For spec'ing or service assistance, call 1-800-826-HELP (4357) 24 hours a day, 7 days a week, (Mexico: 01-800-826-HELP (4357)) for more time on the road.

For the most current information, visit the Roadranger web site at www.roadranger.com

DSS40, DDS40RSS40, RDS40

Dana® Spicer® Drive Axles

Copyright Eaton and Dana Corporation, 2004. EATON AND DANA CORPORATION hereby grants its customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. THIS INFORMATION IS NOT INTENDED FOR SALE OR RE-SALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.

Illustrated Parts List AXIP-0342 July 2004

Table of Contents

1

IntroductionModel Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2How to Use Illustrated Parts List . . . . . . . . . . . . 3Model Identification . . . . . . . . . . . . . . . . . . . . . . 4

Single ReductionForward Axle - DSS40(P), DDS40(P). . . . . . . . . 5Rear Axle - RSS40, RDS40 . . . . . . . . . . . . . . . 13

Piston Air Shift UnitPiston Air Shift Unit . . . . . . . . . . . . . . . . . . . . . 16

Axle Housings & ShaftsAxle Shaft Configurations . . . . . . . . . . . . . . . . 18Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . 18DSS40(P) / RSS40 . . . . . . . . . . . . . . . . . . . . . 19

YokesAll DSS40, DDS40. . . . . . . . . . . . . . . . . . . . . . 20All RDS40, RDD40 . . . . . . . . . . . . . . . . . . . . . 21

AppendixRing Gear and Pinion Identification . . . . . . . . . 22Pinion Bearing Spacers - DSS40(P), RSS40, DDS40(P), RDS40. . . . . . . . . . . . . . . . . . . . . . 22Drive Pinion and Gear Set . . . . . . . . . . . . . . . . 23New Carrier Assemblies . . . . . . . . . . . . . . . . . 24

Introduction

2

IntroductionModel ListingThe following models are represented in this publication.

Single Reduction ModelsForward Axle Rear Axle Axle Capacity Gear Size

DSS40(P) RSS40 40,000 lbs 18” Gear

DDS40(P) RDS40 40,000 lbs 18” Gear

Introduction

3

How to Use Illustrated Parts ListOrdering Parts• This parts book is organized in sections according to parts ser-

vicing requirements. Use the Contents or page headings and colored tabs to find information.

• Use this book to order parts for your Dana® Spicer® Axle.

• For convenience, part numbers have been included for all pieces of the carrier assembly. Some of these parts, such as the carrier and caps, are serviced only in kits or assemblies. Part numbers are for your reference only. Those parts not serviced separately are identified with NSS.

Kits and Assemblies• Kits and Assemblies contain groups of individual or assembled

parts developed for optimal replacement or repair of a service problem.

• Kits and Assemblies are shown with applicable parts groupings in the parts listing.

• See the Appendix for detailed information concerning kits appli-cable to this model.

Abbreviations• A/R-As Required - Parts that vary in quantity with each axle.

Example: shims.

• NSS-Not Serviced Separately - Items which can only be pur-chased in sets, kit form or service assemblies. Example: brake shoes.

• RH/LH - Right Hand/Left Hand - Determined as viewed from behind the vehicle looking forward.

• “RTV” - Gasket Compound - Formed-in-place gasket sealer. It is recommended for use on all surfaces requiring a gasket.

• Assy - Assembly

• Brg - Bearing

• Diff - Differential

• Hsg - Housing

• Inv - Involute

• IASS - In Axle Speed Sensor

• ABS - Antilock Brake System

• N/A - Not Applicable

• Str - Straight

Illustrations• Illustrations show parts in assembly groups.

• Item numbers on illustrations correspond with parts listings on pages that accompany the drawings.

• Notes are included on illustrations where needed.

Parts Listings• Parts listings are defined by parts groupings and are broken

down by service assemblies.

• Parts listings identify a part for servicing with the following cat-egories:• Item - corresponds with numbers on illustrations for part identification• Description - specifies part name or description• Quantity (Qty) - quantity required for assembly• Current Part - service part numbers are broken down by model, type or other applicable information• Notes - define unique characteristics or replacement notes• Kits and Assemblies - indicated Kits or Assemblies that con-tain a particular part

• Other pertinent information is listed in tables or parts listings as required.

Effectively using a parts listing - Example• Follow the example below to locate and order exactly what is required for servicing.

Match to itemson illustration Use to identify Part

Order this quantityfor servicing

Order PartNumber by Model indicated

Indicated information importantto ordering or use

Item Description Qty Part No. Notes

84 Lock washer 10 90417 See Axle Shaft Chart

85 Pipe Plug 1 90325

Kits and Assemblies

Basic Overhaul Kit 1 122437 Contents identified with *

Oil Seal & Shim Kit 1 118111 Includes 33, 46, 75, 78, & RTV

Introduction

4

Model Identification

Locating Model Designation Information• Axle Model Identification, part Number and Serial Number are located on a tag at the axle centerline. This information will help to locate

information in this book and to identify the correct parts for servicing.

Drive Axles

• The axles illustrated in this book are found on a number of different axle shafts, according to OEM specifications. When ordering replacement axle shafts, note the part number stamped into the flange.

D S S 40 - (P)

D - Tandem Forward Axle with Interaxle DifferentialR - Tandem Rear Axle

Gearing:S - Single ReductionD - Driver Controlled Differential Lock

Super-40TM

GAW Rating x 1000 lb.

(P) - Optional Lube Pump

• Model Number, Part Number and Serial Number are located on the data plate on the axle centerline

Spicer™

MODEL

MADE IN:

PART NO. RATIO

SPEC. SERIAL NO.

CUST. PART NO.

Axle Shaft Part Number

Forward Axle

5

Single ReductionForward Axle - DSS40(P), DDS40(P)

5

42 3 1 69 78

1

10 11

11312

42 43 44 45 47 48 49 46

50

DIFFERENTIAL & RING GEAR

14 15 16 19 20

RH

21

17 18 23 22 26 24 25 22 23 20 16 15

LH

14

110 11

99100

RH

DIFFERENTIAL LOCK

14102

20

101

103 104105 107108

106

Forward Axle

6

5152

53 54 55 56

INTER-AXLEDIFFERENTIALASSEMBLY

57 5859

64 63 6562

60

61

60

THESE PARTSARE MOUNTEDIN POWERDIVIDER COVER –NOTE 1

LUBE PUMP

66 6768

69 70 71 72

96

73

82 8483

74 75 76 78 79 80 81

77

95

27 17 2829

3031 33

3235

3431

2836

3740

38 3741

90 89 86 82 87 92

85 97 91 88 94 93

NOTE 1: See page 11 for design change information.

39

Forward Axle

7

Item Description Qty DSS40(P) DDS40(P) Notes

BASIC OVERHAUL KIT 509302 509305 Contents identified by *

1 Diff. Carrier & Bearing CapsCarrier Casting No. 128282C (NSS)

1 509303 – Includes items 2-5, 6-14

Diff. Carrier & Brg. Cap Kit Carrier Casting No. 110500 (NSS)

1 – 508472

2 Bearing Cap Screw 4 127180 32732

3 Flat Washer 4 32912 32912

4 Lockwire 4 12563 12563

5 Dowel Bushing 2 32730 32730

6 Bearing Cap Adjuster Lock (LH & RH) 2 14275 –

Bearing Cap Adjuster Lock (RH) 1 – 14275

7 Bearing Cap Adjuster Lock (LH) 1 – 45448

8 Adjuster Lock Cap Screw 2 210601 210601

9 Cotter Pin (LH & RH) 2 90876 90876

10 Filler Plug 1 90325 90325

11 Carrier Cover Dowel Pin 2 7641 7641

12 Thrust Screw Jam Nut 1 210184 210184

13 Ring Gear Thrust Screw 1 126193 126193

14 Diff. Bearing Adjuster (RH) 1 39448 –

– 82451

Diff. Bearing Adjuster (LH) 1 21637 21637

15 Diff. Bearing Cup (RH) 1 19529* 21632*

Diff. Bearing Cup (LH) 1 15092* 15092*

16 Diff. Bearing Cone (RH) 1 27666* 102660*

Diff. Bearing Cone (LH) 1 27876* 27876*

17 Ring Gear & Drive Pinion Set 1 See Chart See Chart Page 22

18 Bolt 16 67586 67586 In Kit 70745

19 Nut 16 60600 60600 In Kit 70745

WHEEL DIFF CASE KITS Includes items 20-21

3.55-4.11 98610 217619

4.33-6.67 121845 217620

20 Diff. Cases – –

Plain Half (LH) NSS 86777 86777

Flange Half (RH) NSS – –

3.55-4.11 88501 128980

4.33-6.67 126234 128981

21 Diff. Case Cap Screw 12 88503 88503

WHEEL DIFF. SIDE GEAR KIT 120739 123292 Includes items 22-26

WHEEL DIFF. KIT w/o SIDE GEAR KIT 118749 118749 Includes items 23-26

22 Diff. Side Gear 2 120052 – 41 Involute

– 93401 36 Involute

23 Side Gear Thrust Washer 2 27274* 27274*

24 Side Pinion 4 86780 86780

25 Side Pinion Thrust Washer 4 86781* 86781*

26 Spider 1 86778 86778

27 Pinion Pilot Bearing 1 126187* 126187*

Note 1: New design parts beginning February 2000. See Page 11 for more detail and reference Dana Bulletin ABIB-0102.

Forward Axle

8

28 Pinion Bearing Cone 2 129562* 129562* Inner & Outer, Was 14218

29 Pinion Bearing Spacer Washer 1 78904* 78904*

30 Pinion Bearing Spacer AR See Chart See Chart Page 22

31 Pinion Bearing Cup 2 129561* 129561* Was 14217

32 Pinion Bearing Cage & Cup Assy 1 78914 78914 Cage #78932, Includes Item 31

33 Pinion Bearing Cage Shim AR

.003" 45461* 45461*

.005" 62829* 62829*

.010" 45462* 45462*

.020" 62830* 62830*

.030" 113131* 113131*

34 Pinion Bearing Cage Capscrew 6 62158 62158

35 Lockwasher 6 37207 37207

36 Pinion Helical Gear 1 119995 119995

37 Outer Pinion Bearing & Race - Before 2/2000

1 78916* 78916* Note 1

38 Outer Pinion Bearing Snap Ring - Before 2/2000

1 78937* 78937* Note 1

39 Pinion Support Bearing - After 2/2000 1 120080 120080

40 Pinion Shaft End Nut 1 126182 126182

41 Pinion Nut Spring Pin 1 118807 118807

42 Output Shaft Nut 1 210508 210508

43 Output Shaft Washer 1 210509 210509

44 Output Shaft Yoke 1 See Chart See Chart

45 Rear Bearing Retaining Washer 1 78922* 78922*

46 Axle Housing Cover Assy Includes Items 47-50

(Cover 78923R) NSS 1 217647 217647 Replaces 216642, 107863

47 Output Shaft Oil Seal 1 210737* 210737*

48 Bearing Snap Ring 1 78937* 78937*

49 Output Shaft Bearing Race – Inner 1 118787* 118787* Order #78936 Brg Assy

Output Shaft Bearing Race – Outer 1 118788* 118788* Order #78936 Brg Assy

50 Magnetic Filler Plug 1 75130 75130 7/8"

Cover Plug 1 90898 90898 1/2"

51 Output Shaft Kit(Shaft 129016, 41 Splines 2.100" dia) NSS

1 122419 122419 Includes Items 42, 43, 52, 56Replaces 119991

52 Output Shaft "O" ring 2 78931* 78931*

53 Output Shaft Bearing Cup (Inner) 1 24328* 24328*

54 Output Shaft Bearing Cone (Inner) 1 24330* 24330*

55 Output Shaft Side Gear 1 78911 78911

56 Side Gear Snap Ring 1 85994* 85994*

57 Output Shaft Compression Spring 1 127095 127095

58 Output Shaft Thrust Bearing 1 51228 51228

INTER-AXLE DIFF. CASE KIT 1 211252 211252 Includes Items 60-62

59 INTER-AXLE DIFF. ASSY - COMPLETE 1 512845 512845 Includes Items 60-65Replaces 121681

60 Inter-axle Diff. Case Half (NSS) 2 126151 126151

61 Case Bolt 8 57636 57636



Forward Axle

9

62 Case Nut 8 57637 57637

63 Side Pinion 4 95218 95218


65 Spider 1 130904 130904 Replaces 126152

66 Helical Side Gear Snap Ring 1 78909* 78909*

67 Helical Side Gear & Bushing Assy(Side Gear 113328) NSS

1 113331 113331 Includes Item 68

68 Helical Side Gear Bushing 2 75063 75063

69 Helical Side Gear Thrust Washer 1 79034* 79034*

70 Helical Side Gear "D" Washer 1 56360* 56360*

71 Lockout Sliding Clutch 1 119948 119948

72 Input Shaft Kit(Shaft 129017, 46 Splines 2.350" dia.) NSS

1 122418 122418 Replaces 119990Includes Item 81

73 Input Shaft Bearing Cone 1 98387* 98387*

74 Input Shaft Bearing Cup 1 98388* 98388*

75 Input Bearing Cover Shim AR

.003" 78918* 78918*

.005" 78919* 78919*

.010" 78920* 78920*

.020" 113130 113130 Not in overhaul kits

.030" 113131 113131 Not in overhaul kits

76 Input Bearing Cover, Cup & Oil Seal Assy (Cover 111690) NSS

1 509643 509643 Includes Items 74, 78

77 Bearing Cover Cap Screw 5 126243 126243

78 Input Shaft Oil Seal 1 210736* 210736*

79 Input Yoke & Slinger 1 See Yokes, Page 20

80 Input Shaft Nut Washer 1 126242* 126242*

81 Input Shaft Nut 1 126155 126155

82 PDU Cover AssyNon-Pump Models

1 510792 510792 Note 1

Diff. Carrier Cover AssyPump Models

1 510793 510793 Note 1

83 Carrier Cover Cap Screw 8 90069 90069 (short)

1 9309 9309 (long)

1 81855 81855 (socket head)

84 Lockwasher 10 90417 90417

85 Pipe Plug 1 90325 90325

86 Expansion Plug 1 9797 9797

87 Magnetic Filter Screen 1 102611* 102611*

LUBE PUMP REPLACEMENT KIT 121302 Includes items 88-94, 97

88 Lube Pump Cover 1 102607 102607

89 Pump Drive Gear 1 119946 119946

90 Drive Gear Locknut 1 111451 111451

91 Cover "O" Ring 1 102620* 102620*

92 Cover Dowel Pin 2 102617 102617

93 Cover Cap Screw 4 102618 102618

94 Lockwasher 4 90419 90419


Note 1: New design parts beginning February 2000. See for more detail and reference Dana Bulletin ABIB-0102.

Forward Axle

10

95 AIR OPERATED LOCKOUT ASSY - COMPLETE

1 217794 217794 Reference Page 11

96 Shift Fork & Push Rod Assy 1 103529 103529

97 Pump Gear & Shaft Assy

2.188" Shaft 1 102625 102625 Order Complete Lube Pump

2.438" Shaft 1 111779 111779 Order Complete Lube Pump

98 Gasket Compound AR 107276S* 107276S* Not Illustrated

99 Expansion Plug (Upper) 1 30703 30703

100 Shift Fork Shaft 1 113801 113801 Includes 113140 O-ring

101 Expansion Plug (Lower) 1 9797* 9797*

102 Sliding Clutch 1 E935088 E935088

103 Shift Fork & Roller Assy 1 84508 84508

104 Shift Unit Mounting Stud 2 119863 119863

105 Shift Fork Seal & Spring Assy 1 119855 119855

106 Shift Unit Assy 1 See Piston Air Shift Unit Page 16

107 Flat Washer 2 119857 119857

108 Stud Nut 2 63028 63028

Kits and Assemblies DSS40(P) DDS40(P)

Basic Overhaul Kit 509302 509305 Contents Identified with *

Oil Seal & Shim Kit 118111 118111 Includes 31, 45, 73, 76 & 97

Lube Pump Replacement Kit 121302 121302 Includes 86-92, 95, 96

Wheel Diff. Case Kit 98610 98610 Ratios 3.55-4.11Includes Items 18-19

Wheel Diff. Case Kit 121845 121845 Ratios 4.33-6.67Includes Items 18-19

Wheel Diff. Side Gear Pinion Kit 120739 123292 Includes Items 22-26

Wheel Diff. Kit Less Side Gears 118749 118749 Includes Items 23-26

IAD Diff. Case Kit 211252 211252 Includes 58-60

IAD Complete 512845 512845 Includes 58-63



Forward Axle

11

In February 2000, a product upgrade was made to the power divider section of the DSS/DDS40(P) models. The outer pinion support bearing was upgraded from a three-piece bearing assembly & snap ring design to a one-piece roller bearing design. The new bearing part-no. 120080 has a higher load capacity and the assembly procedure is now simplified.

As part of the change, new production power divider covers 129965 (pump models) and 129969 (non-pump models) were released. The 120080 bearing can only be used with these new covers. The older power divider covers that are machined with a snap ring groove are no longer available and are replaced in service by Power Divider Cover kits. The new kits will also include the new 120080 support bearing. The older design bearing parts (78916 and 78937) will remain available for service as shown on the chart below.

Shown below is a quick reference chart for power divider cover castings for both “pump” models and “non-pump” models.

Part Number Description

New Service Replacement

Part-No. Notes

103526, 103536, 117311 PDU Cover - Pump Models 510792 Includes new 129965 cover & 120080 brg

129459, 508497 PDU Cover - Non - Pump Models 510793 Includes new 129969 cover & 120080 brg

129965 New PDU Cover order kit above Pump models

129969 New PDU Cover order kit above Non-Pump models

78916 Outer Pinion Brg & Race Assy still available Use only with OLD style PDU covers

78937 Outer Pinion Brg Snap Ring still available Use only with OLD style PDU covers

120080 New Outer Pinion Brg current Use only with NEW style PDU covers

High Entry 4x4, 6x6 and Military applications not affected by this change

Power Divider Stamped Part Number Model TypeReference

Casting Number

103526, 103536, 117311, 129965, 510792 pump models 103526C

129459, 508497, 129969, 510793 non pump models 129459C

Forward Axle

12

Differential LockoutCast Iron Cover Lockout - February 1996 to Present (Single Reduction Models)

Early Models: Cylindrical Design Lockout

Item Description Qty Order Part No. Notes

COMPLETE LOCKOUT KIT W/SHIFT FORK 1 217794 Includes items 1-8

COMPLETE LOCKOUT KIT W/O SHIFT FORK 1 508457 Includes items 3-8

1 Shift Fork Assembly 1 103529

2 Compression Spring 1 031038

3 Piston Stop 1 129153

4 O-Ring 1 210180

5 Piston 1 129150

6 Lock Nut 1 128160

7 Cast Iron Piston Housing 1 129149

8 Cap Screw 2 090031

Item Description Qty Order Part No. Notes

1 Cap Screw 2 210381

2 Lock Washer 2 90415

3 Mounting Bracket 1 NLA

4 Piston Housing 1 NLA

5 Lock Nut 1 128160

6 Piston 1 NLA

7 Piston O-Ring 1 210180

8 Shoulder Washer 1 NLA


10 Shift Fork & Push Rod Assy 1 103529

*NLA - No Longer Available

1 2 3 4 5 6 7

8

10 89

76

5 4

3 2 1

Rear Axle

13

Rear Axle - RSS40, RDS40

11 12 13 16 19 21 22 18 19 14 16 13 12 11

17 18 20 15 15

3428 27 29 26 27 24 31

24 2514 30 32 336 5 1

2 4 310

8 9

1 23

LH

16 11 36 1

3538

37 3940 43 42 41

Rear Axle

14

Item Description Qty RSS40 RDS40 Notes

BASIC OVERHAUL KIT 122434 217622 Contents identified by *

DIFF. CARRIER & BEARING CAP KIT1 Carrier Casting No 127220-C 1 98593 – Includes items 2-4, 7

Carrier Casting No 127218R 1 – 98590 Includes items 2-4, 40-44

2 Bearing Cap Screw 4 127180 –

2 – 127180

2 – 32732

3 Flat Washer 4 32912 –

2 – 32912

4 Lockwire 4 12563 12563

5 Bearing Cap Adjuster Lock 2 14275 –

Bearing Cap Adjuster Lock (RH) 1 – 14275

6 Cotter Pin 2 90876 90876

7 Dowel Bushing 2 32730 32730

8 Bearing Cap Adjuster Lock (LH) 1 – 45448

9 Dowel Bushing Adjuster Lock 2 37746 37746

10 Capscrew 2 210601 210601

11 Diff. Bearing Adjuster (RH) 1 21637 21637

Diff. Bearing Adjuster (LH) 1 39448 82451

12 Diff. Bearing Cup (RH) 1 15092* 15092*

Diff. Bearing Cup (LH) 1 19529* 21632*

13 Diff. Bearing Cone (RH) 1 27876* 27876*

Diff. Bearing Cone (LH) 1 27666* 102660*

14 Ring Gear & Drive Pinion Set 1 See Appendix: Gear & Pinion Information

15 Bolt 16 67586 67586 In Kit 70745

Nut 16 60600 60600 In Kit 70745

WHEEL DIFF. CASE KITS3.55-4.11 98610 217619

4.33-6.67 121845 217620

WHEEL DIFF. SIDE GEAR KIT 120739 114472 Includes items 21-25

WHEEL DIFF. KIT w/o SIDE GEAR KIT 118749 118749 Includes items 22-25

16 Diff. Case (Flanged Half) NSS

3.55-4.11 1 88501 128980

4.33-6.67 1 126234 128981

Diff. Case (Plain Half) NSS 1 86777 86777

17 Diff. Case Cap Screw 12 88503 88503

18 Diff. Side Gear 2 120052 – 41 Involute

2 – 93401 36 Involute

19 Side Gear Thrust Washer 2 27274* 27274*

20 Side Pinion 4 86780 86780


22 Spider 1 86778 86778

23 Pinion Pilot Bearing 1 126187* 126187*

24 Pinion Bearing Cone (Inner) 1 27239* 27239*

Pinion Bearing Cone (Outer) 1 14218* 14218*

25 Pinion Bearing Spacer* AR See Appendix: Gear & Pinion Information

* Note: Pinion Bearing Spacer information is included in the Appendix: Gear & Pinion Information

Rear Axle

15

26 Pinion Bearing Cage & Cup Assy(Production # 128976)

1 210592 210592 Cage # 079245 Includes Item 27

27 Pinion Bearing Cup (Inner) 1 27238* 27238*

Pinion Bearing Cup (Outer) 1 14217* 14217*

28 Pinion Bearing Spacer Washer 1 078904 31366

29 Pinion Bearing Cage Shim AR

0.003 67920* 67920*

0.005 67921* 67921*

0.010 67922* 67922*

0.020 67923* 67923*

0.030 67924* 67924*

30 Bearing Cage Cap Screw 6 130187 130187 Replaces: 113327 & 128532

31 Oil Seal 1 210724* 210724*

32 Input Yoke 1 See Yokes, Page 20

33 Flat Washer 1 210509 210509

34 Pinion Nut 1 210508 210508

Differential Lock

35 Expansion Plug (Lower) 1 9797 9797

Expansion Plug (Upper) 1 30703* 30703*

36 Sliding Clutch 1 E935088 E935088

37 Shift Fork & Pin Assy 1 84508 84508

38 Shift Fork Shaft AssyShaft #41103 NSS

1 113801 113801 Includes 113140 O-ring

39 Shift Fork Mounting Stud 2 119863 119863

40 Shift Fork Seal & Spring Assy 1 119855* 119855*

41 Stud Nut 2 63028 63028

42 Flat Washer 2 119857 119857

43 Shift Unit Assy 1 See Piston Air Shift Unit, Page 16

44 Gasket Compound AR 107276S* 107276S* Not Illustrated

Kits and Assemblies RSS40 RDS40

Basic Overhaul Kit 122434 217622 Contents identified with *

Wheel Diff. Case Kit 98610 217619 Ratios 3.55-4.11 / Includes Items 16-17

Wheel Diff. Case Kit 121845 217620 Ratios 4.33-6.67 / Includes Items 16-17

Wheel Diff Side Gear & Pinion Kit 120739 114472 Includes Items 18-22

Wheel Diff Kit Less Side Gears 118749 118749 Includes Items 19-22

Oil Seal & Shim Kit 122436 122436 Includes Items 29, 31, & RTV

Item Description Qty RSS40 RDS40 Notes

* Note: Pinion Bearing Spacer information is included in the Appendix: Gear & Pinion Information

Piston Air Shift Unit

16

Piston Air Shift UnitPiston Air Shift Unit

12

9

10

131415

17

16

18

19

20

21

11

22

3 5 1 4 2 6 8 237

26

24 25

61804-6-94

Piston Air Shift Unit

17

Kits and Assemblies


1 COVER ASSY 1

DD Models - cover# 73484 -NSS 129032 Includes Item 2

RD Models - cover# 73485 -NSS 129033

2 Cover Bearing 1 73481

3 Screw & Washer Assy 7 88053 Self-Tapping

4 Cover Gasket 1 73488

5 Cover Plug 1 28325

6 Actuating Lever Pin 1 73456

7 Clevis Pin 1 73498

8 ACTUATING LEVER, PIN & BLOCK ASSY 1

DD Models 129025

RD Models 129029

9 Shift Hsg Cover 1 73490

10 Seal Ring 1 73492

11 Cover Bolt 4 73491

12 Lock Nut 4 47641

13 Lock Nut 1 73496

14 Washer 1 111406

15 Piston 1 73493

16 Felt Piston Oiler (strip) 2 96916

17 Piston O-Ring 1 32832

18 Grommet 1 32826

19 Push Rod 1 73497


21 Piston Stop 1 73495

22 HOUSING ASSY 1 Includes Items 3 & 23 and 84805 Bushing (part not shown)

DD Models 82428

RD Models 82429

23 Housing Bearing 1 73481

24 Switch 1 129035

25 Nylon Washer 1 129034

26 Wiring Harness 1 129044 Metri-pack 150 series

129046 Metri-pack 280 series (Mack Only)

129047 Weather Pack

DD Models

Air Shift Unit 129006

Piston Air Shift Unit & Wiring Harness 129068 Incls Items 1-25 & Wiring Harness 129044



RD Models

Air Shift Unit 129038




Axle Housings & Shafts

18


Axle Shaft ConfigurationsAxles are built with a number of different axle shafts, on the basis of OEM specification.When ordering replacement axle shafts, note the part number stamped into the flange.

Axle Shafts

1 = Freightliner2 = Kenworth3 = Peterbilt4 = Volvo White5 = Mack6 = Western Star

Model Part No. Qty Spline Body O.D.

Shaft Length

Spline Length

Flange O.D.

Flange Holes OEM

DDS40RDS40

110888 2 41 1.87 41.313 8.50 .635 STR 1, 2, 3, 4

129330 2 41 1.87 41.500 8.50 .948 TPR 5, 6

129332 2 41 1.87 40.690 8.50 .773 STR 4

DDS40RDS40

129141* 1 36 2.06 40.600 11" 8.50 .948 TPR 1

126880 1 36 2.06 40.600 4" 8.50 .948 TPR 1

129140* 1 36 2.06 40.600 11" 8.50 .773 STR 4

128055 1 36 2.06 40.600 4" 8.50 .773 STR 4

129139* 1 36 2.06 41.375 11" 8.50 .635 STR 1, 2, 3, 4

129508 1 36 2.06 41.375 4" 8.50 .635 STR 1, 2, 3, 4

* = Diff Lock Shaft w/11” Splines, and are used in sets.


19

DSS40(P) / RSS40


1 Axle Shaft 2 See Chart Page 18

2 Adjuster Nut - Inner 2 119881

3 Bearing Adjuster Lockwasher 2 119883

4 Tanged Lockwasher 2 129132

5 Adjuster Nut - Outer 2 119882

6 Axle Housing 1 N/A See OEM - Housings Vary

7 Axle Housing Cover Assy 1 216642 Casting # 78923

8 Magnetic Drain Plug 1 54254

9 Magnetic Filler Plug 1 75130

10 Cover Locating Dowel 1 7641 Forward Axle Only

11 Cover Cap Screw 1 79558 Forward Axle Only

7 128533 Forward Axle Only

12 Cover Stud 4 49982 Forward Axle Only

13 Nut 4 42364 Forward Axle Only

14 Lockwasher 4 90415 Forward Axle Only

15 Stud 4 36435 Forward Axle Only

16 Stud 8 36435 (short) Rear Axle Only

4 51212 (long) Rear Axle Only

17 Nut 4 90208 Forward Axle Only

18 Nut 12 90208 Rear Axle Only

19 Lockwasher 4 90422 Forward Axle Only

20 Lockwasher 12 90422 Rear Axle Only

21 Cap Screw 2 99708 (12 pt.) Forward Axle Only

6 128532 Forward Axle Only

22 U-Tube Breather Kit 507162 Not Illustrated

5 4 3 2

18 16 18 21 2020

Axle HousingID Tag

1314

1412

1011

7

17 1915

6

Yokes

20

Yokes

All DSS40, DDS40Forward Axle - Input / 46 - 2.350 Involute Spline, Hub Dia. 3.19"

Forward Axle - Output / 41 - 2.100 Involute Spline, Hub Dia. 3.00"

Dimensions (in inches): Replaces Old Straight Spline Yokes

Yoke & Seal Kit Series Joint

Angle Style A B C Dana/Eaton Spicer Rockwell

210843* SPL 170 25° X 6.53 2.16 5.51

210845* SPL 250 25° X 6.76 2.36 5.31

216471 1710 30° Y 6.01 1.94 6.09 82468 6-4-4581 17NYS39-3

216473 1760 30° Y 6.20 1.94 7.00 109639 6-3-4-131

216476 1810 22.5° X 6.01 1.94 7.55 84886 6.5-4-1991 18NYS39-3

216477 82N/8C 30° X 4.75 N/A 6.88 119420

* Yoke and slinger only. Purchase oil seal separately.


Yoke & Seal Kit Series Joint

Angle Style A B C Dana/Eaton Spicer Rockwell

216479 1610 45° Y 6.50 1.88 5.31 99714 5-4-5031 16NYS34-7

216480 1710 38° Y 6.62 1.94 6.09 83800 6-4-4591 7NYS34-8

216481 1760 38° Y 5.81 1.94 7.55

216482 1810 30° Y 5.81 1.94 7.55 87512 6.5-4-2291 8NYS34-1

* Yoke and slinger only. Purchase oil seal separately.

C

A

B

A

C

B C

A

STYLE XHalf Round

STYLE YFull Round

STYLE ZHalf RoundTapped HolesBearing Strap

Yokes

21

All RDS40, RDD40Rear Axle - 41 - 2.100 Involute Spline, Hub Dia. 2.50"

Yoke & Slinger Assy**


Series Joint Angle Style A B C Dana/

Eaton Spicer Rockwell

128882 1610 26° Y 5.19 1.88 5.31 99715 5-4-5031 16NYS34-7

128883 1610 37° Y 6.00 1.88 5.31

128884 1710 28° Y 5.19 1.94 6.09

128885 1710 42° Y 6.12 1.94 6.09 83801 6-4-4591 7NYS34-8

128886 1760 30.5° Y 5.25 1.94 7.00

128887 1810 30° Y 5.25 1.94 7.55 87513 6.5-4-2291 8NYS34-1

128888 72N/7C N/A Z 4.25 N/A 4.62 106459*

210853 SPL 170 25° X 5.32 2.16 5.51

210855 SPL 170 45° X 6.68 2.16 5.51

* Mechanics part number 272715.

** Yoke and slinger only. Purchase oil seal separately.

Appendix

22

AppendixRing Gear and Pinion Identification• Ring Gear and Drive Pinion are matched parts and must be replaced in sets.

• Complete identification is stamped on both parts shown in the adjacent drawing.

• Order by Dana "Set No." which includes drive pinion nut.

Pinion Bearing Spacers - DSS40(P), RSS40, DDS40(P), RDS40Pinion Bearing Spacer size is equal to thickness in inches. The most commonly used spacers are indicated with an asterisk*.

Size " Part # Size " Part # Size " Part # Size " Part #

0.167 91679 0.176 91688 0.185 91702* 0.194 91719

0.168 91680 0.177 91689* 0.186 91704* 0.195 91720*

0.169 91681 0.178 91690* 0.187 91706* 0.196 91721

0.170 91682 0.179 91691* 0.188 91708* 0.197 91722

0.171 91683 0.180 91692* 0.189 91710* 0.198 91723*

0.172 91684 0.181 91694* 0.190 91712 0.199 91724

0.173 91685 0.182 91696* 0.191 91714 0.200 91725

0.174 91686 0.183 91698* 0.192 91716 0.201 91726

0.175 91687 0.184 91700* 0.193 91718* 0.202 91727

Single ReductionRing Gear

Pinion

Matched Gear Set Number Part Number

Ring Gear Teeth

Manufacturing Numbers

L7038 88678 39-6 EA-93JF-19

L7038

Side

Self Locking Nut

Front

Pinion Teeth

Manufacturing Numbers

Part Number 6-39 JD779385

405

EATON

Ring Gear Teeth Pinion Teeth

Appendix

23

Drive Pinion and Gear SetSingle Reduction - 18" Gearing Forward Axle Models: DSS40(P), DDS40(P)

Single Reduction - 18" GearingRear Axle Models: RSS40, RDS40

Ratios Kit # Gear (NSS) Pinion (NSS)41, 2.100" Dia.

3.55 122667 126678 (39) 126679 (11)

3.70 122334 98160 (37) 126161 (10)

3.90 123333 99900 (39) 127047 (10)

4.11 122335 94381 (37) 126162 (9)

4.33 122336 78856 (39) 126163 (9)

4.56 122337 78858 (41) 126164 (9)

4.88 122338 78860 (39) 126165 (8)

5.29 211333 127339 (37) 127327 (7)

5.43 122339 78862 (38) 126166 (7)

6.17 122340 78864 (37) 126167 (6)

6.50 212890 128028 (39) 128029 (6)

6.67 213287 107888 (40) 128052 (6)

Ratios Kit # Gear (NSS) Pinion (NSS)41, 2.100" Dia.

3.55 122668 111349 (39) 126677 (11)

3.70 121887 88500 (37) 126120 (10)

3.90 123334 99896 (39) 127048 (10)

4.11 121888 88502 (37) 126121 (9)

4.33 121889 52999 (39) 126118 (9)

4.56 121890 73312 (41) 126125 (9)

4.88 121891 53001 (39) 126119 (8)

5.29 211335 127338 (37) 127328 (7)

5.43 121892 53003 (38) 126122 (7)

6.17 121893 53005 (37) 126123 (6)

6.50 212891 128030 (39) 128031 (6)

6.67 213288 53007 (40) 128054 (6)

Appendix

24

New Carrier AssembliesThese assemblies are complete, less input yoke and diff. lock shift units.

P = Pump

Single Reduction Models41 Involute Splines

Single Reduction w/Diff Lock36 Involute Splines

Gear RatioForward Assy Rear Assy

DSS40 DSS40-P RSS40

3.55 675638 675583 675575

3.70 675571 675600 675576

3.90 675572 675584 675577

4.11 675876 675585 675578

4.33 675573 675586 675579

4.56 675574 675587 675580

4.88 N/A N/A N/A

5.29 676113 675632 675633

Gear RatioForward Assy Rear Assy

DDS40 DDS40-P RDS40

3.55 675602 675588 675928

3.70 675603 675589 675594

3.90 675604 675590 675595

4.11 675605 675601 675596

4.33 675606 675591 675597

4.56 675607 675592 675598

4.88 N/A N/A N/A

5.29 675608 675593 675599

Appendix

25

Service Kit: 217590

D-Input D-Output R-Pinion

SealPart Number

210736 210737 210724

D-Input D-Output R-Pinion

Location

Tool Number Used

210749

210750

210751 210749

AXIP-0342 07/04 PDFPrinted in USA

The Roadranger® System is an unbeatable combination of the best products from Eaton and Dana – partnering to provide you the most advanced, most trouble-free drivetrain in the industry. And it's backed by the Roadrangers – the most experienced, most expert, most accessible drivetrain consultants in the business. Visit our web site at www.roadranger.com. For spec'ing or service assistance, call 1-800-826-HELP (4357) 24 hours a day, 7 days a week, (Mexico: 01-800-826-HELP (4357)) for more time on the road.

For the most current information, visit the Roadranger web site at www.roadranger.com

DSS40, DDS40RSS40, RDS40

Dana® Spicer® Drive Axles

Copyright Eaton and Dana Corporation, 2004. EATON AND DANA CORPORATION hereby grants its customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. THIS INFORMATION IS NOT INTENDED FOR SALE OR RE-SALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.

Illustrated Parts List AXIP-0342 July 2004

dana spicer drive axles...• use this book to order parts for your dana® spicer® axle. • for...

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